OVERVIEW OF SAINT GOBAIN AND INTRODUCTION TO...
Transcript of OVERVIEW OF SAINT GOBAIN AND INTRODUCTION TO...
HIGH-PERFORMANCE REFRACTORIES
OVERVIEW
OF
SAINT GOBAIN
AND
INTRODUCTION TO
REFRACTORY SOLUTIONS
FOR GASIFICATION
BY
SHAILESH DOSHI
CERAMIC MATERIALS
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Saint-Gobain: History and Overview
Sectors of Activity
Refractory solutions for Gasification
AG
EN
DA
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Saint Gobain History
1665 : creation of the Saint-
Gobain Group, on industrial basis
19th century, the beginnings of
the European scope
20th and 21st century, the
transformation of the Group
Other applications
Other building materials
Other high-performance materials
Distribution of building materials
3 business sectors today
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2016 net sales
€39.1 BN
KEY FIGURES
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Present in
67 countries
One of the top100 industrial
groups in the world with around
950 production sites
More than170,000 employees
and 100+ nationalities represented
Around 4,100sales outlets
Created more than
350 years ago
More than 80% of sales
are made in the habitat markets:
construction, renovation,
infrastructures and civil
engineering
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21 %
12 %
43 %
8 %
16 %
THE GROUP’S MARKETS
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AS A % OF NET SALES
New residential construction
New non-residential construction
Renovation
Civil engineering and infrastructure
Industry
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Cavaillon France
Aubervilliers France
Shanghai China
Chantereine France
Herzogenrath Germany
Chennai India
Capivari Brazil
Northboro USA
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INNOVATION MINDSET
* Source: Clarivate Analytics
3,700 people
8 cross-business
R&D centers
One of the top 100Global Innovators*
390 patents filed in
2016
Partnerships with universities
and start-ups
About 100development centers
3 months in average:
the usage time its takes
for our insulation solutions
to offset the CO2
emissions attributable to
their production
1 product out of 4 sold by Saint-Gobain today didn’t exist 5 years ago
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INNOVATIVE MATERIALS
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The four cockpit windows and 32 passenger
windows of the Falcon 8X are supplied
by Saint-Gobain Sully
Novelio Nature
Range of fiberglass wall coverings from
Saint-Gobain Adfors
NORTON I-HD
New technology from Saint-Gobain
Abrasives that is revolutionizing the
market for diamond tools
MAIN BRANDS PRODUCTS AND ARCHITECTURAL PROJECTS
FLAT GLASS
CONTRAFLAM®
Fire-retardant and anti-UV glazing by Vetrotech in the
futuristic boarders’ residence in Le Rosey, Geneva,
designed by Bernard Tschumi
AUTOMOTIVE GLAZING
ABRASIVES
FLEXIBLE TUBING
BEARINGS
POLYMER SEALS
TECHNICAL TEXTILES
FIRE RESISTANT GLASS
WINDOW FILM
ARCHITECTURAL
MEMBRANES
ADHESIVE FOAMS
CERAMICS FOR ENERGY
REFRACTORIES
ELECTROCHROMIC GLASS
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6 large R&D multi-business centers, many dedicated centers and local teams
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Ceramic Materials
68 manufacturing facilities in 18 countries
7,500 employees
Products:
All divisions produce grains and powders, ceramic components and refractories,
specialty crystals and associated systems.
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Silicon Carbide (SiC)
Abrasive materials
ZirPro – Zirconia beads and powders
NorPro – ceramic solutions for oil and gas exploration and catalyst bed supports
Ceramic refractories (SEFPRO for glass-making furnaces and HPR for other applications)
Particle filters for Diesel engines
Photonics – sapphire wafers for LED, optical windows, medical and industrial lasers
Scintillators – radiation detectors
Quartz - products based upon synthetic silica and fused quartz (crucibles, fibers, rods, tubes)
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Saint-Gobain Ceramic Materials manufacturing facilities
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Rödental
Bollène Le Pontet Avignon
Courtenay
Mudanjiang
Worcester, MA
SiC
Abrasive Materials
ZirPro
NorPro
SEFPRO
HPR
DPF
Crystals
Quartz
Puerto Ordaz
Barbacena
Tirupati
Shanghai
Xining
Phuentsholing
Hody Anaheim, CA Beijing Handan Deng
Feng
Brisbane
Bryant, AR Daisy, TN
Huntsville, AL
Steinefrenz
Guanghan
Vénissieux Gières
Bangalore
Vinhedo
Rainford
Düsseldorf Weilerswist
Thomastown
Northampton, MA
Provins
Lillesand
Arendal
Niagara Falls
Niagara Falls, NY
Wheatfield, NY Amherst, NY
Fort Smith, AR
Buckhannon, WV Olyphant, PA Latrobe, PA
Mezzocorona
Palakkad
Sakai
Chiba
Linyi Lianyungang Jinzhou
Nemours
Larchant
Vallauris
Milford, NH
Hiram/Newbury, OH Canton, OH
Boulder, CO
Riverport, KY
Stow, OH
Bryan, TX
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Innovative Materials
Construction Products
Packaging
Building Distribution
SAINT-GOBAIN GROUP, HPR DIVISION
Flat Glass
High Performance Materials
Abrasives Crystals Textile
Solutions Plastics
Ceramics
Grains &
Powders
Ceramic Materials
High Performance Refractories Division
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WTE Gas Turbines
Iron
Gasification
Aluminium Steel
Foundry Petrochemical
Kiln Furniture Firing Systems Insulators
WRT
Process
Components HX
Armor
Muffles
Norfoam Liquid Filtration
REFRACTORIES ENGINEERED CERAMICS
HIGH PERFORMANCE REFRACTORIES MARKETS SERVED
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# 13
Industrial footprint – 2017
Niagara Falls
Vénissieux
Worcester
Vinhedo
Rodental
Latrobe
Rainford
Bangalore
Seto
Shanghaï
11 High Performance Refractories locations
* 6 locations shared with Sefpro for Electrofused products
Halol
Pallakad *
Perundurai *
Bejing * Mezzocorana *
Le Pontet *
SGTM *
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Reforming CarbonBlack
Fertilizers Chemicals
Alternative Energies Nuclear
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Gasification
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REFRACTORY SOLUTIONS
FOR GASIFICATION
CERAMIC MATERIALS
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GASIFICATION TECHNOLOGIES
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E Gas
by P 66
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ENTRAINED FLOW GASIFIER TYPICAL LININGS
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Refractory lined option available, but less popular
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ENTRAINED FLOW GASIFIER LININGS - SCHEMATIC
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(Or bricks)
Back up
(Chrome
or
Alumina) Alumina Or
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GASIFICATION SYSTEMS
Refractory solutions for slagging and non-slagging gasifiers Texaco / GE E-Gas Siemens
Material qualitites for various feedstocks Natural gas Oil Coal Petcoke Biomass Municipal waste
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TECHNICAL SOLUTIONS - GASIFICATION
Solids gasification High chromia refractories
Liquids gasification High alumina refractories
Design / Calculation
/ Supervision
AH199, AL100 1st layer Zirchrom
MS2R 2nd layer Chromcor
AN599,RI34,SiC,MS6 3rd layer
MS6,RI34, SiC
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Refractory solutions from A Z
Full refractory design
Thermal Calculations
FEM analyses
R&D support for refractory analyses and
assessment
Product preassembly and inspection
Installation supervision
Individual package solutions for each customer
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LABORATORY TESTS-CORROSION
SAINT-GOBAIN R&D CENTER CAPABILITIES
Crucibles Test
(50 x50 x 20)
-Isotherm, static
Multiple cycles
Dimensional before and after corrosion
Finger test
(180 x 25 x25)
-Material corrosion by dynamic molten slag under reducing atmosphere
-Tmax: 1600°C
-3 samples/1 reference material
-Dimensional before/after corrosion (triple point or immerged part)
-2-10 rpm
Rotary kiln
(Arch brick 33 x 200)
-Evaluation of slag infiltration by dynamic molten slag
-Presence of thermal gradient
-Determination of wear > 1%
-T: 1600-1650°C
Hot abrasion test
-Evaluation of abrasion I nhot medium and impact on wear
-Tmax: 1600°C
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LABORATORY TESTS-CORROSION
SAINT-GOBAIN R&D CENTER CAPABILITIES
Wettability Test
- Determination of Slag Melting temperature
- Comparative refractory analysis
- Impact of additives on Slag Viscosity
Thermal Shock testing
- Thermal shock in air
Thermal shock in water
- Determination of residual strength
- Comparative analyses
Strength
- Cold crushing strength
- Hot MoR (T=1400°C)
- MoR (20°C)
Material analyes
- Chemical composition
- Crystal structure
- XrayDefraction
- Hot Xray Deflection
- SEM
- Mircorprobe
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Chromium oxide products
Zirchrom®
(chrome-zirconia):
Zirchrom®30V
Zirchrom®400
Zirchrom®60/60V
Zirchrom®750
Zirchrom®85V
Zirchrom®90
Zirchrom®900
(chrome-alumina)
Chromcor®12
Monochromcor® 10
Chrpmcor® B/B10/BDAK
Aluminium oxide products
AL100
AL102 / AL102V
MS2R
MS4
MS6
Alundum® AH199H
Alundum® AH191
Alundum® AN599
Allfrax® 101HF
Mullfrax®202HF
Mlullfrax® 201
Zirconium oxide products
Ziral14
Ziral94M
ZiA95
ZH192
ZH392
ZS739
Sh
ap
es
Bricks
Monolithics
Ramming&Towelling mix
Pro
ce
ss
Automatic press
Maxibrator press
Vibrocasting
Slipcasting 24
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Complicated shapes Maxibrator shaping
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Large shapes Vibrocasting
Chromia Qualities
Alumina Qualities
Up to 1500kg/pce
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Big series Automatic Press
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Al203 – Cr2O3 – ZrO2 system
ZrO2
Cr2O3
Thermal shock
resistance Hot mechanical
strength
Corrosion resistance (slag, glass)
Impurities
(SiO2 < 10%)
Ziral 14/AH199BZ
Al2 O3
ZC 900
ZC 85V
ZC 60
AL100/ AH199 Ziral 94M/ZA95 CC B10 CC BDAK
ZC30V
AL102
ZC400
ZC 90
ZC 750
CC12
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AL100 family Product Al2O3 SiO2 Fe2O3 CaO Alkalins P2O5 Others
% % % % % % %
AL100 99.5 0.1 0.1 - - - <0.3
AL102 96.0 1.2 0.1 ZrO2 2.5
- - <0.2
MS2R 87.0 12.4 0.1 0.2 - - <0.3
MS4 70.0 29.5 0.3 - - - <0.2
MS6 62.0 36.5 0.9 TiO2 0.25
- - <0.3
RI34 98.5 0.7 0.1 - - - <0.3
Product Density Porosity Max service temp
Thermal conductivity
g/cm3 % °C W/mK
AL100 3.32 16.0 1800 3.8
AL102 3.30 15.5 1800 -
MS2R 3.05 14.0 1650 -
MS4 2.5 18.0 1650 2.2
MS6 2.53 14.0 1600 1.85
RI34 1.50 - 1800 1.25
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Alfrax® Family
AL 100
Product Al2O3 SiO2 Fe2O3 CaO Alkalins P2O5 Others
% % % % % % %
Alfrax 101 98.7 0.1 0.1 0.1 0.25 - <0.5
Alfrax 201P 92 5 0.5 0.5 0.3 2.8 <0.5
Alfrax 301P 91.5 3.5 0.5 0.1 0.2 0.5 <2.0
Alfrax B101 98.4 1.3 0.1 0.1 0.3 - <0.5
Alfrax B202 81 17 0.3 (TiO2 0.2)
0.9 - <0.5
Mullfrax 201 78 21 0.2 - 0.4 - <0.5
Mullfrax 202 87 12 0.1 (TiO2 0.1)
0.5 0.5
Product Density Porosity Max service temp
Thermal conductivity
g/cm3 % °C W/mK
Alfrax 101 3.00 22 1800 2.7
Alfrax 201P 3.05 11 1800 2.8
Alfrax 01P 3.10 13 1800 3.4
Alfrax B101 1.48 58 1800 -
Alfrax B202 1.44 49 1800 1.1
Mullfrax 201 2.60 18 1750 1.6
Mullfrax 202 2.80 18 1800 2.0
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ZirchromTM/ChromcorTM family
AL 100
Product Al2O3 SiO2 Cr2O3 ZrO2 Others
% % % % %
Chromcor BDAK 80.0 6.0 10.0 4.0 <0.3
Chromcor 12 87.0 - 12.5 - <0.5
Zirchrom 30 41.8 10.0 30.0 18.2 <0,3
Zirchrom 400 43.5 6.5 39.0 10.0 <1.0 (0.8 Fe2O3)
Zirchrom 60 17.0 9.0 62.0 12.0 <0.3
Zirchrom 750 11.0 9.0 71.0 7.5 <1.0 (0.7 Fe2O3)
Zirchrom 900 - 5.0 88.0 7.0 <0.3
Product Density Porosity Max service temp Thermal conductivity
g/cm3 % °C W/mK
Chromcor BDAK 3.55 12 1800 -
Chromcor 12 3.35 17 1750 4.4
Zirchrom 30 3.45 14 1750 2.9
Zirchrom 400 3.72 13 1800 -
Zirchrom 60 3.84 10.0 1800 2.9
Zirchrom 750 4.05 12.0 1800 -
Zirchrom 900 4.15 12.0 1800 -
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Technical solutions - Gasification Production of syngas (CO + H2 ) from hydrocarbons
For ammonia, methanol production, synfuels, energy
High process temperature (Tmax 1600°C)
Various feedstock:
Natural gas
Oil
Coal
Petcoke
Biomass
Municipal waste
Heavy oil
Energy
Flame
Plasma torch
Low CO2 emissions
Lot of molton ash
No or very few molton ash
Refractory lined:
Withstand high temperature
Insure corrosion resistance
Insure thermal shock resistance
Optimize process and maintenance 33
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Technical solutions - Gasification Burner
Feedstock inlet
Dome
Reaction zone
1st refractory layer 2nd refractory layer 3rd refractory layer
Molton ash deposition Cone
Syngas and
molton ash output
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Technical solutions - Gasification
Solids gasification High achromia
refractories
Liquids gasification High alumina
refractories
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Summary
Refractory experience since more than 60 years
Customizes solutions
Strong R&D support
Worldwide production and support facilities
Access to Saint-Gobain products network
High quality products over a long time
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THANK FOR YOUR ATTENTION !